Still had a few sitting around the shop....

These 2...one to be split down the middle, the other for a lid's panel..

2 of the 4 squares I have...pick of the litter?....need a bunch of "sticks"..

Also a few to make "slips" for the bottom panel to reside on. So....

Set up the rip fance to cut a bunch of sticks....to make the frames to hold the 5 panels..

Here is MOST of the sticks..

And those 4 panels?   Well they were ripped to 2-5/8" width.  The 2 end panels will need to be trimmed to match the width of the top's panel width...

Cut a pair of long rails, and a pair of short stiles/legs ...some were not quite the same thickness...so..

We have ways to make them all match....Reset the tablesaw...with a zero clearance overlay..

Blade sticks up about a 1/4" above the panel...Trying to mill a groove.    Parts are too small to use the Stanley 45 to make the grooves, too hard to jig it up, so the part will stay put...and still allow the use of the plane's fence.   First cuts..

One pass along each side....second setting is to remove the strips in the middle..

Goal for today....to get a dry fit of one side of the box....setting up all the steps needed...Like tenons to go into the groove to form the corners...cut away to sides of the leg's groove to make a foot pattern....that the ends frames will have to match.  Laundry Detail today, errands to run, finger to be poked...managed to get the grooves for the second side milled....and stopped for the day....

 

The panels for the sides needed flattened....to match the groove better...The were already ripped down to width...first rip was close, adjust the fence a hair...NOW they match.  Then the 2 ends were ripped to match.  Been using the Stanley 358 Mitre Box to trim parts as needed...it also made the shoulder cuts for the tenons on the stiles, bandsaw does the cheek cuts....finesse with a 1" wide, SHARP chisel.

 

Maybe tomorrow, I can get a little something done, in the shop?

 

Stay tuned..

 

No rest for the weary

3 hours ago, lew said:

No rest for the weary

 

 

Exactly, he didn't even let me get off work before he is halfway done.  I don't have popcorn at work.   

Laundry Detail, today....getting side #2 ready to glue up.

Not everything was square...we have ways..

Reset this, to help lay out for the tenons...

So they would fit the grooves better...

Panel was a bit too fat....shooting a little off the edges, test for fit...

That should do it...test/dry fit...

Need to remove the clamps from side #1..

And get ready to glue up #2..

And, in theory, those clamps I just removed from #1 should go right in place on #2....yeah, right

So, a little hep was needed to tame this herd of cats..I mean Boards..

The vise makes a great 3rd hand....even when I need 4 hands.....

Then carefully move this out onto the bench, and get the rest done...

 

Then set aside...had more parts to mill...box will need ends, right?

One task...was to figure out how the ends' stile will get milled....not enough wood there for T&G stuff..needs two cuts..

It has it's own curved foot, but, it also needs to match the front ( or Back) foot's curves..

So you can't see it from the front, or back...

 

One of the end panels was a bit too thick...we have ways..

Go across the grain at a slight diagonal..thins things right down....but a bit on the rough side...so.

Change from a No. 15  Jack to a No. 9 smoother...

 

Grooves have been milled in the stiles, rails have been cut to length, after grooves were also milled in them,...dryer is done, so am I

 

I think it is about time for one ( OR more) of these...( BTW, I also managed to get the yard mowed....new blade seem to work nicely enough..)

 

Stay tuned..

Gunny, pass the popcorn. Another installment of "The Dungeon Workshop" is under way. But, what happened to Igor? 

Travel Restrictions, Igor is stuck over in Transylvania....they won't even let him fly my broom home

Just an update...leg is still sore.   Got Side #2 out of the Forest of Clamps, and held it up to Side #1......Not really a good "match"

 

Side #1 was a hair longer, one stile was out of square...fixed that..try again?

Hmmm, we have work to do....plane and beltsander work...

(other end was about the same, too)

getting there...when this was FINALLY fixed up...I then removed one clamp, and rotated the two sides in the vise, trying NOT to shift things around...

As one topside didn't quite match the other...we have ways..

Millers Falls N0. 9, type 4  ( the last GOOD type they made.)  Some of that line is from a gap between the 2 sides...

As the tops are now leveled, and match.   have been getting parts for the 2 ends fine tuned for fit....panels so they will fit into the grooves, need to mark out and bandsaw the feet profiles, and mill a few (8 !) tenons....then see about 2 glue ups...Stay tuned

Bought popcorn from gas station this morning. Was ready this time.

 

After an attack of diverticulitis, popcorn is veboten. Peanut butter M&Ms will have to do. But, man I sorely miss my popcorn. Just don't take too long, Bandit. I'm already too fat.

Ok...Leg still sore. Only spent an hour in the shop today...had trouble going up and down the steps...

 

Anyway.  Tasks were to shape 3 more feet... and mill 8 tenons. Goal was to get a decent fit..

Mitre box for the shoulder cuts, bandsaw for the cheek cuts..still needed a trim..

A little fat on the left side..had that nice SHARP chisel handy, to pare away any extras...

Dry fit, after that foot got it's profile sawn.  Decided to go ahead and glue this one up....

Whether it wanted to, or not...it was getting glued up.  Then work on the other end assembly...

Last 2 feet.  More tenon work...got one tenon a might too skinny...tried a dry fit, anyway..

Figure the clamps will pull things together.  That will be tomorrow, I hope.  I'll take the clamps off the other end assembly, and clamp this one up..with a decent amount of glue, brushed around, of course. 

 

Need to figure out the size of the lid's frame...and get to working on that..

Stay tuned...

Finally, after chasing parts across the bench, and removing the needed clamps from the #1 End....

And throwing one c clamp into the trash ( YOU"RE FIRED!!!) #2 End is glued up, and sitting in the clamps, whether it wanted to, or not.

Set this aside, part of today's one shoptime.   Checked the #1 End over...

Legs look..chunky...and just plain too fat.   Maybe IF I mill a tongue onto the end's legs, to fit into a groove....may even skinny things down a bit..

Hmm, not quite deep enough?    Made over on the tablesaw, rip fence right up against the side of the blade...Raise the blade just enough to leave that tongue...by going over the blade twice, to mill both sides of the tongue.    Reset the fence one blade with away from the blade...and go again...had an issue with the second pass....had a fat section....

we have ways...

 

Set the cutter to the correct depth, and scrape away the high spot.   Chisel to complete the clean up.

 

Reset the tablesaw, needed grooves to house the tongues...took 2 settings, to get it wide enough..had to watch how deep the cuts were...was getting a bit close to another glue joint....dry fit?(After milling 4 grooves..)

A little skinnier.   A view from above...gets complicated..

You have the T&G that connect the stiles to the rails.   I did not want to cut into that one, as it would just split off.  Left a little bit to glue to.

 

Tomorrow, when the #2 End comes out of the clamps, I can mill the tongues on it.  Tongue cutter for the Stanley No. 45 just isn't narrow enough, @ 3/16" width.  These tongues are about..1/8"...barely.  Can use #1 End to reset the saw to match...after I make sure the two ends match each other...

 

I also started on a frame for the lid....cutting parts over on the Mitre Box...

Figured out how long to make the 2 rails, and cut them...

Also cut the 2 stiles/ends...

 

Tried the panel...it was way too long, but also way too narrow....means I'll need to add more width....either on the edges, or, right down the middle.

 

At this point, I just called it a day....plenty of time tomorrow, eh?

 

Stay tuned....

About 1 hour of shoptime, today.....#2 End is out of the clamps....needed to get cleaned up a bit..

Both this face and the outside face needed planed and sanded level and smooth....

So did the top and bottom edges....Set up the rip fence and the blade height..

2 passes, then move the fence a hair away from the blade..

A bit of fine tuning with a chisel, and a block plane...they need to fit into these.

Grooves.   Enough that a dry fit could be attempted?

Hmm, then get out the glue, more clamps, and a brush....

With one longer clamp to pull the diagonals.....and the box, into square. I set the mess on it's top, first...right on a sheet of plywood....wanted the "top" pieces to all be flush with each other....C clamps to pull the two halves of each foot together...

Tomorrow ( or the next day ) Clamps can come off, and the glue joints can all be cleaned up, back to bare wood....

 

Was I done for the day? Not exactly....lid panel needed some work..

Panel was too long, and needed that "defect" removed.   Those 2 strips are how much the panel needs to "grow" in width...Trim for length..

No biggie...plenty of room...Had to joint one edge, first...

Now, I suppose there are some out there , that need to use the "Shooting Board" to true up after an end has been sawn, but...

Since this is how things come off the mitre box,  no shooting board is ever needed. 

 

One more glue-up, and call it a day..

Those 2 strips were glued up, to add width to the panel.   The 3 c clamps are hold a caul in place, to keep THAT end flat....vise is doing the same job, too.

 

Need to build a frame to go around this panel, once it is trimmed to final size.   Need another panel for the box's bottom....and, something for it to sit on.

 

Stay tuned..

I'm exhausted and out of both beer and popcorn.

I am just going to bed.  Whew!  I've had more than I can handle.  LOL

Switched to chocolate covered pretzels. Ran out of M&Ms. 

About 2 hours of shoptime, and an hour of processing pictures...everybody stocked up on snacks?  Here we go...

Clamps came off today..

 

And the box was set up on it's own four feet..

Hey, at least it sits level...Move things around for a bit...needed to mill some "slips"

That the Stanley #358 can cut to size...

Don't worry, it will soon be back to the 90 degree setting, first I need a few miter joints made...

This one first...then glue and clamps..

Then the other 3 sides..

.

let this sit a spell...as for the lid blank?

This might take a bit of work...we have ways..

.

One face wasn't too bad...the other took a bit longer...

Was a busy day..

Just from flattening that panel...one end needed sawn for square...the other end was a tad too long..

#358 back to 90 degrees, trim both ends...squared up first, THEN mark for length..

This was before all the trimming was done...can't use the tablesaw..

It's in there, somewhere...had to use the mitre box.   Not having the tablesaw also meant I had to do grooves a bit differently

Feeling Groovy?  There are 3 screws holding this in place..this one is to tighten the grip on the one in front..

And there is one along the backside to keep the part from walking away...screwheads are below the depth setting.  Test fit of the panel to the groove...

Had to bevel the "inside" face of the panel...for a better fit...got the 2 ends done..

I used that Millers Falls No. 15 Jumbo Jack to make the bevels....when I bevel the long grain edges, that divot will go away...

 

Clean up! Aisle No.1!.....

And we be done for the day...area between the shoulder blades is HURTING...twas a busy day...

may try tomorrow to actually get something done?

Stay tuned..

 

Guess I had better update this a bit?

 

Anyway...glue-ups are all done..

Both the box...

And the lid...

A bottom was installed...after slips had been glued in place..

Needed to get the box and the lid "on the same page"

 

Then do a little rounding over...finishing the rounding overs today..ends?

and the front and back edges of the lid..

Then hinges were done, despite their not wanting to( one even tried to run away..)

Laid out on the lid, first..

Round up the usual suspects..

Uses the 2 tap system...2 taps on the end of the chisel with the mallet, move a bit, repeat...then slice out the chips..Made sure these 2 mortises lined up with the marks on the box...and work on that..

And trying to keep the dang thing from walking away...2nd hinge did.   Then try to connect the box to the lid...cussing was involved

Nope..not the easiest thing to do...finally got things attached...clamped the box shut...we have other things to do..

Scratch Awl to start the 4 holes, nail in the drill's chuck is a pilot hole thingy...and that MIGHT be a Klein screwdriver...Then set this mess onto the bench, get out a can, and a Church Key..

And brush on the first of many coats...of Amber Shellac..

 

Just a simple, little box....a way to use up a bit of scrap lumber.  Need to rub this over in a little bit, and add a 2nd coat...and repeat as needed...still have a pint left in that can...

 

Stay tuned

 

Love it!

Some beautiful work.  No shop time tonight, had to work on pressure washing house and driveway.  Will be a few days before that is done, unless heavy rain.